PHOTOCATALYST COMPRISING TiO2 AND ACTIVATED CARBON MADE FROM DATE PITS

ABSTRACT

A photocatalyst is provided that comprises activated carbon produced from date pits, impregnated with TiO 2 . The activated carbon can have a porous surface that can attract and trap pollutants flowing in air or water. The photocatalyst can be made by a method that includes preparing activated carbon by calcining date pits to form a precursor material, and then impregnating the precursor material with titanium dioxide.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.12/725,010, filed Mar. 16, 2010, which is incorporated herein in itsentirety by reference.

FIELD

The present teachings relate to photocatalysts suitable for theadsorption and decomposition of organic molecules and environmentalpollutants.

BACKGROUND

Photocatalysis relates to the phenomenon of transforming light energyinto chemical energy. There are many materials, such as, SrTiO₃, ZnO,ZnS, CdS, and TiO₂, for example, that are considered to be efficientphotocatalysts. TiO₂ is characterized by having an energy band gap inthe range between 3 and 3.2 eV. Light energy and the electron band gapenergy of TiO₂ are compatible or equivalent to ensure effectiveinteraction of TiO₂ material with UV light. TiO₂, as a photo-activematerial, can therefore, efficiently utilize energy from sunlight andtranscend in photocatalyzing chemical reactions. For instance,absorption of a photon by a TiO₂ crystal enables excitation of anelectron (e⁻) from the valence band to the conduction band if the photonenergy, h_(v), equals or exceeds the band gap energy of TiO₂.Simultaneously, an electron vacancy or a positively charged hole (h⁺) isgenerated in the valence band:

h_(v)+TiO₂→e⁻+h⁺

The electron-hole pair (e⁻+h⁺) that is created migrates to the TiO₂photocatalyst surface triggering redox reactions to take place withcompounds adsorbed to the surface of the photo-catalyst and/or in thesurrounding medium. For TiO₂, photo-generated positive holes have redoxpotential of ca. 2.5 eV against normal hydrogen electrode (NHE), thispotential allows production of hydroxyl radicals from water. Whereas,the redox potential of photo-generated electrons (−0.52 eV) is capableof reducing oxygen O₂ to superoxide (O₂ ⁻) or hydrogen peroxide (H₂O₂).Hence, there are sufficient redox potentials to initiate a chain ofredox reactions that can lead to decomposition of most organicmolecules.

Thus, because of its inherent photoactivity, TiO₂ can be an efficientphotocatalyst. A need exists, however, for a photocatalyst that canadsorb and decompose organic molecules and/or environmental pollutants.In particular, a need exists for a substrate that can be used with TiO₂to provide a photocatalyst that can efficiently adsorb and decomposeorganic molecules and/or environmental pollutants. Furthermore, a needexists for an economical and environmentally friendly technique forproducing such a substrate.

SUMMARY

Features and advantages of the present teachings will become apparentfrom the following description. This description, which includesdrawings and examples of specific embodiments, provides a broadrepresentation of the present teachings. Various changes andmodifications to the teachings will become apparent to those skilled inthe art from this description and by practice of the teachings.

The present teachings relate to a photocatalyst comprising TiO₂ andactivated carbon. The activated carbon can be produced from date pits.The activated carbon can have a porous surface that is particularlyuseful for attracting and holding pollutants flowing in air or water.TiO₂ can be photoactive and can have the ability to trigger redoxreactions. The photoactivity of TiO₂ and its ability to trigger redoxreactions and the adsorption ability of the activated carbon make thephotocatalyst particularly suitable for adsorption and decomposition oforganic molecules and/or environmental pollutants.

According to some embodiments, the activity and adsorption of activatedcarbon produced from date pits can be comparable to that of activatedcarbon produced from conventional precursor materials, such as wood,coal, or coconut shells. Date pits can provide a particularly idealprecursor for manufacturing activated carbon because of the high contentof carbonaceous material in date pits. Date pits are generally removedduring industrial processing of dates. Thus, date pits can be obtainedin copious amounts with little cost, especially in parts of the worldwhere dates are widely grown. According to some embodiments, date pitscan provide an environmentally safe and economical carbonaceousprecursor for manufacturing activated carbon.

The present teachings further relate to a method comprising contactingdate pits with an acidic aqueous solution, to form treated date pits,and calcining the treated date pits under conditions to cause thetreated date pits to thermally decompose and form activated carbon.According to one or more embodiments, an acidic aqueous solution cancomprise a phosphoric acid solution. In some embodiments, the phosphoricacid solution can comprise a concentration of from about 1% to about 30%phosphoric acid. The treated date pits can be treated at a temperatureof from about 80° C. to about 150° C., for a period of from about onehour to about twelve hours, to dry the treated date pits, prior to thecalcining. The calcining can occur at a temperature of from about 300°C. to about 900° C. The calcining can be conducted under a nitrogenblanket to form a calcined product. The calcined product can be treatedwith carbon dioxide gas. In some embodiments, the activated carbon canbe impregnated with titanium dioxide, to form an impregnated product. Aprecursor compound can be contacted with the impregnated compound tophotocatalyze a chemical reaction.

In some embodiments, the present teachings provide a method foradsorbing organic molecules, pollutants, or both, by contacting theorganic molecules, pollutants, or both, with a photocatalyst comprisingthe impregnated product.

In some embodiments, the present teachings provide a photocatalystcomprising the impregnated product.

In some embodiments, the present teachings provide activated carbon madefrom the method comprising contacting date pits with an acidic aqueoussolution, to form treated date pits, and calcining the treated date pitsunder conditions to cause the treated date pits to thermally decomposeand form activated carbon.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and constitute apart of the specification, illustrate specific embodiments of theinvention, and taken in conjunction with the detailed description of thespecific embodiments, serve to explain the principles of the invention.

FIG. 1 is a schematic diagram showing a photocatalysis reaction setupcomprising an open flow system used for testing catalytic activity,according to various embodiments of the present teachings.

FIG. 2 is a schematic diagram showing another photocatalysis reactionsetup comprising a closed loop setup for testing catalytic activity,according to various embodiments of the present teachings.

FIG. 3 is a schematic diagram showing a photocatalysis reactor accordingto various embodiments of the present teachings, useful in open flow andclosed loop systems.

FIG. 4 is a schematic diagram showing a batch reactor system, accordingto various embodiments of the present teachings.

DETAILED DESCRIPTION

The following detailed description serves to explain the principles ofthe present teachings. The present teachings are susceptible tomodifications and alternative forms and are not limited to theparticular forms disclosed herein. The present teachings covermodifications, equivalents, and alternatives.

According to various embodiments of the present teachings, a method isprovided that comprises contacting date pits with an acidic aqueoussolution, to form treated date pits, and calcining the treated date pitsunder conditions to thermally decompose the pits and form activatedcarbon. The acidic aqueous solution can comprise, for example, aphosphoric acid solution. The concentration of the acidic aqueoussolution can comprise an acidic component present in an amount of fromabout 1% by weight to about 40% by weight, for example, from about 1% byweight to about 30% by weight, about 3% by weight to about 25% byweight, or from about 5% by weight to about 20% by weight. In anexemplary embodiment, the acidic aqueous solution comprises phosphoricacid present in an amount of from about 1% to about 30%, for example,from about 5% by weight to about 20% by weight.

According to one or more embodiments, the acidic aqueous solution cancomprise a phosphoric acid (H₃PO₄) solution. In some embodiments, thephosphoric acid solution can comprise a concentration of from about 1%to about 30% phosphoric acid, for example, from about 5% to about 30%,from about 10% to about 20%, or from about 15% to about 25% phosphoricacid. In some embodiments, the phosphoric acid solution can comprise aconcentration of about 5%, 10%, 15%, 20%, or 25% phosphoric acid. Insome embodiments, other acids such as sulfuric acid, hydrochloric acid,and the like, can be used.

In some embodiments, the treated date pits are heated to a temperatureof from about 80° C. to about 150° C., for a period of from about 1 hourto about 12 hours, to dry the treated date pits, prior to the calcining.The calcining can occur at a temperature of from about 200° C. to about1,000° C., for example, from about 300° C. to about 900° C., from about400° C. to about 800° C., or from about 500° C. to about 700° C. Thecalcining can be conducted under a nitrogen blanket. In someembodiments, the calcining is conducted under a nitrogen blanket to forma calcined product, and the method further can further comprise treatingthe calcined product with carbon dioxide gas.

For drying, the treated date pits can be treated at a temperature offrom about 80° C. to about 150° C., for example, at a temperature offrom about 85° C. to about 120° C., or from about 90° C. to about 100°C. The treated date pits can be dried for a period of from about onehour to about twelve hours, for example, from about two hours to abouteight hours, from about three hours to about seven hours, or from aboutfour hours to about six hours. In some embodiments, the treated datepits can be dried for about six hours at a temperature of about 120° C.Drying can take place at ambient pressure or at an elevated or reducedpressure.

The treated date pits can be calcined under conditions to cause thetreated date pits to thermally decompose and form activated carbon. Thetreated product can be calcined in a manner familiar to those of skillin the art. In some embodiments, both a drying step and a calcinationstep can be carried out at the same time, together. In some embodiments,calcining can be carried out after drying to form activated carbon. Thecalcining can occur at a temperature of from about 300° C. to about 900°C., for example, at a temperature of from about 400° C. to 800° C. or ata temperature of from about 500° C. to 750° C. The calcining can becarried out for a period of time of from one hour to four hours, forexample, from one hour to three hours or from one hour to two hours. Thecalcining can be conducted under a nitrogen blanket.

After calcining to form a calcined product, the calcined product can betreated with a gas, for example, with carbon dioxide gas. The gastreatment can be carried out at an elevated pressure, at a reducedpressure, or at ambient pressure. In some embodiments, the calcinedproduct can be pulverized, granulated, screened, and/or otherwisetreated to form a desired particle size and/or uniformity.

According to various embodiments, a photocatalyst can be made byimpregnating the activated carbon made as described herein, withtitanium dioxide, to form an impregnated product. A method can beprovided for photocatalyzing a chemical reaction by contacting aprecursor compound with the impregnated product. In some embodiments, amethod is provided that comprises adsorbing organic molecules,pollutants, or both, by contacting the organic molecules, pollutants, orboth, with the photocatalyst.

In some embodiments, the photocatalyst can be made by first preparingactivated carbon using date pits as a precursor material, and thenimpregnating the activated carbon with TiO₂. The activated carbon can beprepared by contacting date pits with an acidic aqueous solution, toform treated date pits.

According to various embodiments, the photocatalyst can be prepared bymixing TiO₂ with the activated carbon under conditions sufficient toimpregnate the activated carbon with TiO₂. According to someembodiments, the photocatalysts prepared by mixing TiO₂ and theactivated carbon can exhibit enhanced affinity to adsorption of organicmolecules, such as alkanes and phenols. In some embodiments, TiO₂ in asolution can be mixed with the activated carbon to form a mixture.According to some embodiments, the concentration of TiO₂ in the mixturecan be from about 10% by weight to about 50% by weight, for example,from about 15% to about 40%, or from about 20% to about 30%, by weight.The mixture can be heated for a period of from one to five hours, forexample, from one to four hours, or from one to three hours, and thendried. The mixture can be heated at a temperature of from about 70° C.to about 200° C., for example, at a temperature of from about 80° C. to100° C. or at a temperature of from about 90° C. to 150° C.

According to some embodiments, the photocatalyst can comprise TiO₂particles having one or more sizes, and/or one or more polymorph forms.Examples of TiO₂ products that can be used include those available fromNational Titanium Dioxide Company, Ltd. (Yanbu Al-Sinaiyah, SaudiArabia), for example, as described in U.S. patent application Ser. No.12/584,699, filed Sep. 10, 2009, which is incorporated herein in itsentirety by reference. The TiO₂ can have an average particle size offrom about 0.005 μm to 1 μm, for example, from 0.005 μm to 0.75 μm, from0.01 μm to 0.6 μm, from 0.1 μm to 0.5 μm, from 0.2 μm to 0.4 μm, orabout 0.3 μm. According to various embodiments, any suitable crystallinepolymorph of TiO₂ can be used. In some embodiments, TiO₂ in rutileand/or anatase form can be used. According to some embodiments, the TiO₂particles can be doped with one or more cationic and/or anionic species.Exemplary dopants that can be used include, but are not limited to, Na⁺,Cl⁻, and Al³⁺. According to some embodiments, prior to mixing with theactivated carbon, the TiO₂ can have a surface acidity of from about pH3.6 to about pH 12.8, for example, from about pH 3.8 to about pH 10.5,or from about pH 4.0 to about pH 7.7.

In addition to methods, the present teachings also provide impregnatedproducts, for example, made by the methods described herein, activatedcarbon made from the methods described herein, and photocatalysts madeby the methods described herein.

According to various embodiments, a photocatalyst can comprise titaniumdioxide (TiO₂) and activated carbon that is produced from date pits.Table 1 shows approximate values of date pit constituents. As shown inTable 1, date pits can comprise a high content of carbonaceous material.

TABLE 1 Composition of Exemplary Date Pits Moisture  5-10% Protein (N ×6.25) 5-7% Oil  7-10% Crude fiber 10-20% Carbohydrates 55-65% Ash 1-2%

The date pits can, for example, be immersed in the acidic aqueoussolution for a period of about one hour to about twenty fours hours, forexample, for about eight hours to about fifteen hours, or from about tenhours to about twenty hours.

Finely divided TiO₂ can be used to impregnate the carbonaceous, soaked,dried, and calcined date pit material. Table 2 below shows exemplaryTiO₂ materials (Samples Nos. 1-15) that can be used to form thephotocatalysts of the present teachings. Table 2 also showscorresponding properties of each of the exemplary TiO₂ materials.

TABLE 2 Properties of Exemplary TiO₂ materials for Preparation ofPhotocatalysts TiO₂ Particle Size Crystalline Sample pH Mm PolymorphDopants 1 4.30 0.3-0.6 rutile Cl⁻ & Al³⁺ 2 4.20 0.5-1.0 rutile Cl⁻ &Al³⁺ 3 4.00 0.1-0.4 rutile Cl⁻ & Al³⁺ 4 4.50 0.2-0.5 rutile Cl⁻ & Al³⁺ 54.60 0.005-0.1  anatase Cl⁻ 6 7.10 0.3-0.6 rutile Cl⁻ & Al³⁺ 7 7.400.5-1.0 rutile Cl⁻ & Al³⁺ 8 7.30 0.1-0.4 rutile Cl⁻ & Al³⁺ 9 7.500.2-0.5 rutile Cl⁻ & Al³⁺ 10 7.70 0.005-0.1  anatase Cl⁻ & Na⁺ 11 10.40.3-0.6 rutile Na⁺, Cl⁻ & Al³⁺ 12 10.5 0.5-1.0 rutile Na⁺, Cl⁻ & Al³⁺ 1310.1 0.1-0.4 rutile Na⁺, Cl⁻ & Al³⁺ 14 10.3 0.2-0.5 rutile Na⁺, Cl⁻ &Al³⁺ 15 12.5 0.005-0.1  anatase Cl⁻ & Na⁺

The present teachings are further illustrated with reference to thefollowing examples which are intended to exemplify, not limit, thepresent teachings.

EXAMPLES

To examine the effectiveness of photocatalysts prepared in accordancewith the present teachings, three experimental setups were used. Thefirst setup was a fixed bed reactor 10 comprising an open flow systemthat operates as shown in the flowchart depicted in FIG. 1. The fixedbed reactor can comprise a photocatalysis reactor 12 that is open atopposing ends. A flow of gas, such as purging gas, carrying organicmolecules, flows at a controlled rate into photocatalysis reactor 12.The gas enters at one end of photocatalysis reactor 12 and out anopposing end of photocatalysis reactor 12 through a vent 16. In someembodiments, a mass controller can be used to control the flow rate. Thefeed stream, or gas stream, flowing into photocatalysis reactor 12, isanalyzed by gas chromatography-mass spectrometry (GC-MS) equipment 14 asis the product stream, or gas stream, flowing out of photocatalysisreactor 12.

The second setup, like the first setup, comprises a fixed bed reactor20. Unlike the second setup, however, the second setup comprises aclosed flow system. After the product stream is analyzed by GC-MSequipment 14, it is recirculated through photocatalysis reactor 12(closed system), as shown in FIG. 2. Photocatalysis reactor 12 can beidentical in both the first and second setups. As shown in FIG. 3,photocatalysis reactor 12 can comprise a glass tubular reactor 32 made,for example, from PYREX glass. Tubular reactor 32 can be filled withglass beads 34 followed by introduction of about 3 grams of titaniumdioxide photocatalyst material. After the photocatalyst is disposedwithin tubular reactor 32, tubular reactor 32 can be placed in aUV-cabinet, or container, that enables the entry of UV light only. FIG.3 shows photocatalyst reactor 12 disposed within a UV cabinet.

FIG. 4 shows a batch reactor system 40 comprising a plurality ofphotocatalysis reactors 12. Batch reactor system 40 can be used todetermine the performance of photocatalysts with respect to liquid phasewaste materials. The reacting medium can comprise, for example, aphenol/water system. For the experimental setups described herein, 13 mLof solution containing 40 ppm phenol in water and 0.1 grams ofphotocatalyst, were used. Photocatalysis reactors 12 were placed in thedark or light for a suitable time, then analyzed in a UV/VISspectrometer.

Example 1 Ethane Adsorption on Activated Carbon

Date pits were immersed overnight in an aqueous solution comprising 5%H₃PO₄, then removed, and dried for six hours at 120° C. The treated datepits were then calcined for three hours at 850° C. in the presence ofnitrogen, producing a sample of activated carbon. The produced sample ofactivated carbon had a surface area of 665 m²/g. Two grams of theactivated carbon sample were purged with 1% ethane/air gas at a flowrate of 0.1 ml/min to test its affinity as an efficient adsorbent. Asshown in Table 3, ethane was not detected in the effluent stream for upto about 300 minutes. As such, it was determined that the activatedcarbon sample was an efficient adsorbent.

TABLE 3 Ethane Adsorption on Activated Carbon Surface area ElutedAdsorption Sample (m²/g) Ethane Area Time (min) Activated Carbon 665 0 0(A) 0 46 0 74 0 256 0 298 5411 309

Example 2 Phenol Adsorption on Activated Carbon

An activated carbon sample was prepared by a method similar to thatdescribed in Example 1, except that an aqueous solution comprising 10%H₃PO₄ was used, instead of a solution of 5% H₃PO₄. The activated carbonsample was tested for adsorption affinity to a phenol compound. A sampleaqueous medium was prepared by mixing 40 ppm phenol aqueous solutionwith the activated carbon sample. A second aqueous medium containing amixture of 40 ppm phenol aqueous solution and commercial activatedcarbon was also prepared, for comparison with the sample aqueous medium.The sample aqueous medium, the second aqueous medium, and a referencesolution containing 40 ppm phenol solution were incubated in the dark(in the absence of UV light). Measurement readings using UV/VISspectrophotometer were taken before and after incubation to monitor thepresence of phenol in the aqueous medium, and the results are shown inTable 4.

As shown in Table 4, phenol adsorption of UV/VIS light between initialand final readings decreased. This can be explained by adsorption ofphenol molecules by the activated carbon.

TABLE 4 Phenol Adsorption on Activated Carbon Initial Final Surface areaAbsorption Absorption Sample (m²/g) Reading Reading Activated Carbon (A)665 2.31 0.83 Commercial Activated Carbon 689 2.31 0.70 Standard PhenolSample — 2.31 2.31

Example 3

Activity of Catalysts when Tested in Closed Loop Photocatalysis System

Activated carbon samples were prepared by the method described inExample 1. Each of TiO₂ Sample Nos. 3, 5, 6, and 10 were loaded into arespective activated carbon sample. A closed loop cycle reactor system,as shown in FIG. 2, was used to test the resulting photocatalyst. First,a photocatalysis reaction was performed in the dark, in the absence ofUV light. One to three grams of the prepared photocatalyst was placed ineach tubular reactor of the reactor system. The reactor system was thenflushed with methane. The amount of methane left in the system wasanalyzed by GC-MS every 15 minutes. Then, a photocatalysis reaction wasperformed with UV lights on, that is, in the presence of UV light. Thesystem was again flushed and filled with methane, and the methane wascarried through the tubular reactors. The methane present in the systemwas analyzed by GC-MS every 15 minutes. The results are shown in Table5.

TABLE 5 Activity of Catalysts When Tested in Closed Loop PhotocatalysisSystem TiO₂ Sample % of Methane % of Methane Mixed to Make analyzed inabsence analyzed in presence the Catalyst* of UV-Light of UV-Light 399.16 0.00 5 63.31 0.00 6 25.44 0.49 10 71.73 0.46 *Catalysts calcinedat 850° C. in Nitrogen atmosphere for 3.0 Hr.

Example 4

Reaction of Methane with Light Using Open Reactor System

An activated carbon sample was prepared by the same method described inExample 3, except that calcination was conducted in the presence of CO₂.Each of TiO₂ Sample Nos. 3, 5, 12, and 14 were loaded into a respectiveactivated carbon sample. This time the photocatalysis reaction ofmethane was carried out in an open reactor system, as shown FIG. 1. Themethane gas flow was controlled at 0.1 ml/min to 2 ml/min in thepresence of UV light. The results are shown in Table 6.

TABLE 6 Reaction of Methane with Light Using Open System Reactor TiO₂Sample Mixed to % of converted Make the Catalyst* Methane 3 73.07 599.30 12 87.98 14 56.47 *Catalysts calcined at 850° C. under Nitrogenfor 3.0 Hr + CO₂ for 5 Min

Example 5 Photocatalytic Degradation of Phenol Under Sunlight

Activated carbon was prepared by the same method described in Example 4.Each of TiO₂ Sample Nos. 3, 4, 6, and 10 were loaded into a respectiveactivated carbon sample. Photocatalytic degradation of phenol undersunlight was observed, using the batch reactor system, shown in FIG. 4.The results are shown in Table 7.

TABLE 7 Photocatalytic Degradation of Phenol Under Sun-Light TiO₂ SampleMixed to % in converted Phenol Make the Catalyst* (after 2 hrs) 3 93.734 89.72 6 91.59 10 91.25 *Catalysts calcined at 850° C. in Nitrogenatmosphere for 3.0 Hr.

Example 6 Photocatalytic Degradation of Phenol Under Sunlight

Activated carbon was prepared by the same method described in Example 5.Each of TiO₂ Sample Nos. 3, 4, 6, and 10 were loaded into a respectiveactivated carbon sample. Photocatalytic degradation of phenol undersunlight was observed, using the batch reactor system, shown in FIG. 4.The results are shown in Table 8.

TABLE 8 Photocatalytic Degradation of Phenol under sun-light TiO₂ SampleMixed to % in converted Phenol Make the Catalyst* (after 1 hrs) 3 77.564 76.80 6 86.13 10 80.30 *Catalysts calcined at 850° C. under Nitrogenfor 3.0 Hr + CO₂ for 5 Min

While the present teachings have been described in terms of exemplaryembodiments, it is to be understood that changes and modifications canbe made without departing from the true scope of the present teachings.

1. Activated carbon made from a method comprising: contacting date pitswith an acidic aqueous solution, to form treated date pits; andcalcining the treated date pits under conditions to cause the treateddate pits to thermally decompose and form activated carbon.
 2. Aphotocatalyst comprising an impregnated product produced by a methodcomprising: contacting date pits with an acidic aqueous solution, toform treated date pits; calcining the treated date pits under conditionsto cause the treated date pits to thermally decompose and form activatedcarbon; and impregnating the activated carbon with titanium dioxide, toform an impregnated product.
 3. A photocatalyst comprising animpregnated product produced by a method comprising: contacting datepits with an acidic aqueous solution, to form treated date pits;calcining the treated date pits under conditions to cause the treateddate pits to thermally decompose and form activated carbon; andimpregnating the activated carbon with a solution comprising from 10% byweight to 50% by weight titanium dioxide, to form an impregnatedproduct.
 4. The photocatalyst of claim 3, wherein the solution comprisesfrom about 20% by weight to about 30% by weight titanium dioxide.